Kiln and ceiling structure therefor



Feb. 28, 1956 A. G. BOYLES 2,736,278

I KILN AND CEILING STRUCTURE THEREFOR Filed March 27, 1953 2 Sheets-Sheet l 4a 0 o a o o a o o o o o o 0 0 o o o a /0 o 0 o a o a 40 0 o o o o o o o o o a o 6' a o o 0 c Q a o o o INVENTOR. Alango 6. Boy! 65,

Feb. 28, 1956 A. G. BOYLES 2,736,278

KILN AND CEILING STRUCTURE 'THEREFOR Filed March 27, 1955 2 Sheets-Sheet 2 rPn M INVENTOR. 4/0/75o G Bog/e6,

KILN AND CEILING STRUCTURE THEREFOR Alonzo G. Boyles, New Cumberland, W. Va.

Application March 27, 1953, SerialNo. 345,136 3 Claims. (Cl. 110-99) This invention relates to a kiln construction, and more particularly has reference to a ceiling formation for kilns of the type used for burning brick, sewer pipe, and other clay products.

A kiln of the character referred to is of a domed or crowned formation, so far as the roof thereof is concerned, and it will be understood that the construction of'a domed roof of common brick and fire brick, while not a difficult task, requires expert assistance, and involves a substantial expense.

In view of the above, I propose to provide a kiln having a fiat roof, which kiln will be fully insulated so far as the side wall and roof thereof is concerned, the fiat roof ofthe kiln having superposed layers offire brick and insulating brick, so as to be more efficient in use than those kilns of conventional domed construction. Insulating blocks will be used altogether in the ceiling of'the fiat top type, as well as insulating brick in the inner wall unless it be in places where the insulating material" will not stand erosion, chemicals, etc.

Another object of importance is to provide a kiln as stated in which the flat roof, though formed mainly of superposed layers of fire brick and insulating brick, can be constructed with the bricks laid dry, thus to speedup the construction while at the same time reducing substantially the expense involved.

Still another object is to provide a roof construction for kilns in which the superposed layers of bricks will be suspended from a steel framework disposed thereabove and supported upon the kiln side wall.

Yet another object is to provide a kiln construction as described wherein the steel framework will be particularly' strong and rigid.

Another object is to provide a kiln that will be characterized by its great and long-lasting economy of operation and upkeep or repair.

.Otherobjects will appear from the following description, the claims appended thereto, and from the annexed drawings, in which like reference characters designate likeparts throughout the several views, and wherein:

Figure 1. is a plan section through a kiln formed in accordance with the present invention, taken on line. 1., -1

of:- Figure. 2;

Figure 2. is a vertical section taken diametrically through the kiln, taken substantially on line 2--2 of E re Figure 3. is a greatly enlarged, fragmentary sectional view showing the manner in which the main supporting 1 beam, connected to the auxiliary beams, to, provide a steel framework for the roof;

Figure 4 is .an enlarged transverse sectional view through one of the auxiliary beams, showingthe manner in which: the layers of bricks or blocks are supported therefrom;

Figure 5 is a detail sectional view through the roof, taken from theright of Figure 4;

Figure. 6 is a view similar to Figure 1, showingthe arrangement of the fire boxes of the kiln; 1

States Patent O Figure 7 is a fragmentary, enlarged, vertical sectional view of the kiln shown in Figure 6; and

Figure 8 is a fragmentary side elevational view of the kiln of Figures 6 and 7, showing the fire box and ash pit arrangement, and showing additionally an exterior reinforcing band assembly. I

The kiln constituting the present invention may be of circular or rectangular configuration as desired, the circular configuration shown in Figure l being illustrated purely by way of example. In any event, regardless of the outer configuration of the kiln, said kiln has an outer side wall designated generally by the reference numeral 10, which would, in the preferred embodiment of the kiln construction, be formed of common brick.

Disposed inwardly of the outer side wall 10, and rising to a height somewhat lower than the height of the outer side wall, is an inner side wall designated generally at 12 said inner side wall being formed of insulation brick or the like. It will be understood that insulating brick will be used, unless it be where this material will not stand erosion, such as around furnace liners, or in the presence of chemicals used in firing. In these circumstances, fire brick will be used. In any event, it is proposed that the kiln be properly insulated throughout the area of its side wall.

In the space between walls 10 and 12, insulation 13 is placed. Whether the kiln be domed or made with a fiat ceiling, an insulation lining will be employed. If the materials burned would act chemically on the insulation and cause the same to deteriorate, fire brickwould be exposed to the chemical action with the insulation placed between the fire brick and the outer wall of common brick, as shown. Otherwise, the fire brick inner wall need not be used.

In the domed or crown type of kiln, a fiat layer of common brick at the ceiling would be provided, and would be laid with a coating of cement and 'sand grout or other material to waterproof the same.

At diametrically opposite locations thereon, the outer side wall 10 is formed with vertically extendedreinforcing piers or abutments 14.

A main beam has been designated by the reference numeral 18, and as shown in Figure3, can be of I-beam material. The main beam 18 extends between the piers 14, and has its ends supportedthereupon, the main beam thus being disposed diametrically of the kiln.

The single main beam 18 supports, in cooperation with the side wall of the kiln, a. plurality of auxiliary beams 20 which, as shown in Figure 4; are. also of I'-beam ma terial. The auxiliary beams 20 arev extended. normally to the main beam, and have their outer ends engaged in. recesses 22 provided in the outer side wall; 10, adjacent the top edge of said outer side wall. As. will: be seen from Figure l, the auxiliary beamsv will, if the kiln is of the circular. type, be of different lengths, but if' the kiln were of the rectangular type, the auxiliary beams would all be coextensive in length, with the m.ain;beam. l8;being, in this instance, extended transversely of thekiln intermediate the opposite ends thereof; In such rectangular kilns, if the kiln is too wide forthe side of. an ordinary beam, then a main beam would be placed crosswise of the kiln, with the auxiliary beams extending. lengthwise of the kiln from one main beam to another, for asmany spans as necessary. This, it is believed, isv sufficient-ly obvious as not to require special illustrationherein.

At their inner ends, the auxiliary beamsltl. are. partially cut away as at 24 (Figure 3), to permit the inner end portions of the auxiliary beams to fit over the bottom portion of the main beam 18. In this way, theauxi'liary beams. are supported at their inner ends on said main beam, and to effect a rigid connection between the; auxiliary beams and their associated main beam, tie--. plates 26 are used. The tie plates 26 are spaced longitudinally of the main beam 18, and are extended transversely of said main beam in alignment with the several beams, the tie plates being welded, at their midlength portions, to the main beam as at 28. The projecting end portions of the tie plates 26 are apertured for extension therethrough of bolts 30, said bolts 30 extending through the auxiliary beams, to cause the desired rigid connection of the auxiliary beams to the main beam.

Reference should be had at this time to Figures 4 and 5, in which I have shown the means whereby superposed layers of ceiling blocks are supported from the auxiliary beams. Each auxiliary beam is provided with a plurality of uniformly spaced hanger support plates 32, which plates are disposed transversely of their associated auxiliary beams, the opposite ends of each plate projecting beyond opposite sides of the auxiliary beam. The plates 32 are spaced apart to the extent desired during the construction of the roof, and are then clamped to the auxiliary beams by means of hook-like clamping rods 34 having threaded shanks extending through apertures formed in the plates 32, said threaded shanks being adapted to receive nuts which serve to cause the clamp members to tightly grip the auxiliary beams.

At their opposite ends, the respective hanger support plates 32 are formed with openings receiving the upper ends of vertically disposed hanger rods 36, said hanger rods being provided with nuts at their upper ends, for holding the hanger rods assembled with their associated support plates 32. The use of the nuts, of course, permits the several hanger rods 36 to be adjusted vertically relative to the steel framework constituted by the main and auxiliary beams.

At their lower ends, the hanger rods 36 have eyes receiving horizontally disposed, elongated block support rods 38.

The horizontally disposed support rods 38 are disposed parallel to one another and to the several auxiliary beams 20, each auxiliary beam supporting a pair of rods 38 therebelow, as shown in Figure 4. The support rods 38 are adapted to support a bottom layer of coplanar, rectangular fire bricks 40, the bricks or blocks 4% being disposed in abutting relationship to form a closed roof over the kiln, with the several blocks being disposed in contacting rows. The blocks of each row are each formed with a pair of parallel bores, the bores of the several blocks of the row being aligned for extension of the support rods 38 therethrough.

No mortar or other bonding element is employed between the abutting blocks, and it will be seen that the blocks are so supported from the steel framework as to completely cover the top of the kiln.

The outermost blocks of the ceiling, in this regard,

clear the top edge of the inner side wall 12 as shown in Figure 2, by about one inch to allow for expansion, the space being filled with rock wool 43 or the like.

A second, upper layer of ceiling blocks is employed in the invention, the blocks of the second layer being designated by the reference numeral 44. The blocks 44 are thinner than the blocks 40, but are also of rectangular formation. The blocks 44 are preferably of insulating material, and are disposed in abutting relationship, the joints of the blocks of the upper layer being offset, however, from the joints of the blocks of the lower layer, thus to seal the roof to the maximum extent.

The blocks 40 have recesses 42 formed in their upper surfaces, for extension of the lower ends of the hanger rods 36 thereinto, said recesses 42 being closed by the blocks 44 of the upper layer.

To further seal the roof, it is desirable that the corner joints of the blocks of the upper layer be covered, and to this end, small sealing blocks 46 are used, each block 46 being disposed over the point of intersection of a side of block 44 with a side of a block 40 therebelow. The

longitudinal edges of the blocks 44 each have a pair of recesses to accommodate the hanger rods. Some of the blocks 46 are located in the space between the recesses of each pair. The remaining blocks 46 are located over the end edges of the blocks 44-. The small spaces about hanger rods 36 can, if desired, be filled with pulverized insulating material or the like, but this is not absolutely necessary.

The construction illustrated and described is one that permits a flat roof to be provided upon a kiln of the character described, said fiat roof being easily formed by comparatively unskilled help, at a minimum of expense.

The roof would be provided with a protective covering, not shown, it being preferred that sheet metal over a light steel framework be used.

The kiln shown in Figures 1 and 2 is basically conventional in design, so far as the side wall construction and inner construction thereof is concerned. Thus, the kiln has the usual doorway 48, and would also be provided with the usual fire boxes or furnaces, fire holes, and ash pits.

Referring now to- Figure 6, this figure and Figures 7 and 8, has been included in the drawings to show a preferred side wall constmction of a kiln, that is particularly adapted for use with a ceiling of the type described above. The side wall shown in Figures 6-8 includes an outer side wall portion 5th of common brick or the like, said outer side wall having an inner side wall 52 positioned thereagainst. The inner side wall 52 is of fire brick, and could be so disposed as to permit insulating material to be utilized, either as a part of the inner side wall 52 or between the inner and outer side walls.

Spaced ninety degrees apart about the inner side wall are expansion joints 53 (Figure 6).

The kiln shown in Figures 68 has a plurality of furnaces, said furnaces being spaced equal distances apart about the kiln and including fire holes 54. The kiln also has the usual doorway 56.

Spaced ninety degrees apart about the kiln are cooling openings 58, and mounted upon the exterior surface of the kiln, below each cooling opening 58, is a shelf 60 supporting a blower 62. The blowers 62 can be placed in operation to cool the kiln in a minimum period of time, for reuse thereof. Alternatively, the blower can be utilized for the purpose of distributing heat uniformly throughout the kiln. When the cooling openings 58 are not being used, they would be plugged with insulating material.

It is desirable that the kiln be exteriorly reinforced, and accordingly, a plurality of circular reinforcing bands 64, 66, 68, are spaced vertically of the kiln, said bands extending fully around the kiln. Further, at each fire box, a removable reinforcing framework is utilized, said framework being shown in Figure 8 and including parallel, vertically disposed side members 72 connected at their upper and lower ends to the rings 68, '70. The side members 72 are joined by a cross member 74. The steel framework as noted above is removable, and therefore permits repairs to be made at low expense by comparatively unskilled labor, rather than by expert mechanics.

The fire hole of each fire box includes an outer arch 76 of common brick, said outer arch merging into an arch ring 78 which can be precast or fire brick. Interiorly of the inner arch ring there can be provided insulated arch rings in any desired number, superposed one upon another.

The ash pit opening below each fire hole is provided, overhead, with a steel support plate 80.

The fire hole and ash pit, of course, communicate with a box or fire pocket shown in dotted lines in Figure 7, and designated by the reference numeral 82.

It is important to note that the fire box construction shown in Figures 6-8 is particularly adapted for incor poration in a kiln of the type shown in Figures 1 and 2, having a suspended ceiling. For this reason, a suspended i .1 WA

ceiling of the type shown in Figures 1 and 2 has been shown in Figure 7.

A kiln formed as shown would, it is believed, be considerably more efiicient than conventional kilns now in use.

It will be understood that common or fire brick will be used wherever insulating brick will not suflice.

The importance of the firebox construction is emphasized. It is believed to be a highly attractive design from a commercial standpoint, due to the use of the molded slabs or blocks for the side liners and the molded fire ring.

It is believed apparent that the invention is not necessarily confined to the specific use or uses thereof described above, since it may be utilized for any purpose to which it may be suited. Nor is the invention to be necessarily limited to the specific construction illustrated and described, since such construction is only intended to be illustrative of the principles of operation and the means presently devised to carry out said principles, it being considered that the invention comprehends any minor change in construction that may be permitted within the scope of the appended claims.

What is claimed is:

1. In a kiln, a side wall; a main ceiling beam extending thereacross; a plurality of parallel auxiliary ceiling beams extending normally to the main beam, said auxiliary ceiling beams being supported at one end by the main beam and at their other ends by the side wall; a pair of parallel rows of hanger rods depending from each of the auxiliary beams; a horizontal support rod carried by the hanger rods of each row; ceiling blocks each having a pair of parallel bores receiving adjacent support rods, the several ceiling blocks being disposed in abutting relationship with their upper surfaces disposed in a common plane; a plurality of abutting cover blocks supported on the ceiling blocks, the joints between adjacent cover blocks being olfset in both lateral and longitudinal directions from the joints between adjacent ceiling blocks, said cover blocks having recesses in the edges receiving the hanger rods; and a plurality of sealing blocks supported upon the cover blocks, each sealing block being disposed over the point of crossing of an edge of cover block and an edge of a ceiling block underlying said cover block.

2. In a kiln, a wall structure; beam means extending thereacross; hanger rods depending from the beam means; horizontal support rod means carried by the hanger rods; ceiling blocks each bored for extension of the support rod means therethrough, the several ceiling blocks being disposed in abutting relation with their upper surfaces disposed in a common plane; a plurality of abutting cover blocks supported upon the ceiling blocks, the joints between adjacent cover blocks being offset in both lateral and longitudinal directions from the joints between adjacent ceiling blocks; and a plurality of sealing blocks sup ported upon the cover blocks, each sealing block being disposed over the point of crossing of an edge of a cover block and an edge of a ceiling block underlying said cover block.

3. In a dry-laid ceiling structure for kilns, a bottom layer of abutting ceiling blocks; a layer of abutting cover blocks overlying the ceiling blocks, the joints between adjacent cover blocks being offset in both lateral and longitudinal directions from the joints of adjacent ceiling blocks; and a plurality of sealing blocks supported upon the cover blocks, each sealing block being disposed over the point of crossing of an edge of a cover block and an edge of a ceiling block underlying said cover block.

References Cited in the tile of this patent UNITED STATES PATENTS 1,516,604 Hosbein Nov. 25, 1924 1,612,795 Abbott Jan. 4, 1927 1,709,350 Jackman Apr. 16, 1929 1,793,031 Trachsel Feb. 17, 1931 

